Oxy Acetylene Cutting Machines

Oxy-acetylene cutting, or flame cutting, uses a high-temperature flame from burning both acetylene and oxygen. The process heats ferrous metals to their ignition temperature. A jet of pure oxygen then oxidises the metal, producing molten iron oxide (slag). This is then blown away to create a clean cut. The process is cost-effective, portable, and ideal for cutting carbon steel and other oxidisable metals. However, it is less precise and slower than modern methods like plasma or laser cutting. It still has its place in industry today, used in heavy-duty applications, like repairs, and fieldwork. It's simplicity, versatility, and resource availability are some of the benefits gas cutting can offer.

Gas cutting, or oxy-fuel cutting, is a process used to cut ferrous metals like cast iron and steel. Industries like construction, shipbuilding, and automotive manufacturing, all utilise the gas cutting process. It is ideal for tasks such as cutting structural steel, and fabricating parts. As well as recycling scrap metal, and performing on-site repairs. Its portability and capacity to handle thick materials make it valuable for industrial fabrication, demolition, and maintenance work. It's also used for artistic applications like sculptures and designs, as results offer a very clean, straight edge. Gas profile cutting machines are available as both portable units for on site work, as well as CNC machines or cutting tables for thick sheet cutting in-shop.

 While oxy-acetylene cutting is commonly used for carbon and mild steels, as well as other ferrous metals, it's not the ideal method for cutting stainless steel. The chemical reactions involved in gas profile cutting can lead to unsatisfactory results when applied to stainless steel, including a large Heat Affected Zone (known as HAZ), and distortion. We would recommend using plasma for stainless steel cutting applications, as it gives a much better finish and is designed for thinner sheet steel.

The specific pressure settings can vary depending on the equipment, torch tip size, and the material being worked on. However, there are general guidelines for setting the oxygen and acetylene pressures.

As a guide, try the acetylene regulator at 10 psig, and the oxy regulator for 40 psig for material under 1 1/2" thick.

The oxy-acetylene torch, also known as the oxy-fuel torch, was invented by Edmond Fouche and Charles Picard in 1903. Fouche, a French engineer, and Picard, a French scientist, developed the oxy-acetylene torch for welding and cutting metals, as it's still used for today!

It is not recommended to flame cut cast iron as it's a messy, inconsistent process that can lead to puddling and cracking. The high carbon content in cast iron makes it less reactive to the oxidisation process that oxyfuel cutting produces. It's brittle nature and lack of ductility makes it fracture or crumble under stress, leading to uncontrollable cracks and irregular, rough edges.

A plasma cutter might be a better solution for cutting thinner cast iron sections, alternatively band saws, water jet cutting, and milling or lathe cutting can be used for precision work or complex shapes.

The choice between an oxy-acetylene cutting machine and a plasma cutter depends on various factors, including the type of work, the materials, and your specific requirements.

Oxyacetylene and gas profile cutting are best for thicker mild and low carbon steels, also, no electricity is needed, so it's ideal for applications where portability is an important factor like fieldwork. The outlay and operational costs are also fairly cheap compared to other methods. However it is a slow process, and doesn't work well when cutting stainless steel, aluminium, or non-ferrous metals.

On the other hand, plasma cutting cuts through all conductive metals (steel, stainless steel, aluminium, copper etc.), and offers faster, cleaner cuts with minimal heat distortion. It works best for cutting thin-medium material thicknesses (1mm-50mm), depending on the machine's power output. The initial equipment cost is higher than flame cutting, and it also requires an electrical supply as well as compressed air. Plasma cutting isn't a suitable process for thick metals, but if you need speed, precision and versatility on thinner sheet metal, a plasma cutter is the way to go.

Many metal fabricators use a combination of both methods based on the application, as found on a CNC plasma gas profile cutter. Check out our guide to help you choose between flame cutting or plasma cutting here.

Flame or oxyfuel cutting has it's benefits for the right application. See the below advantages and disadvantages to help you weigh up if it's the right process for you.

Advantages:

• If you're cutting thick steel, it's proably one of the only cutting processes you can use effectively. You can gas profile cut steel sheets over 150mm (6 inches) thick! Making it ideal for heavy-duty industries like structural steel fabrication.
• No electricity required - the process only requires oxygen and fuel gas, making it great for portable use in fieldwork and remote locations.
• Low equipment cost, making the initial investment cheaper than a plasma or laser cutting alternative.
• The oxyacetylene process itself is very versatile, and can be used for cutting, welding, brazing and heating purposes too!
• No limit on cutting length, compared to other processes restricted by table sizes

Disadvantages:

• Oxyfuel cutting is limited to ferrous metals, therefore can't be used to cut stainless steel, aluminium, or non-ferrous metals.
• Cutting speeds are slow, particularly on thin materials compared to processes like plasma and laser.
• The excessive heat generated produces more heat distortion and warping on thinner metals.
• Additional finishing processes like grinding are usually required due to the rough edges and slag.
• Storing of gas cylinders (oxygen and fuel gases) and proper handling can be a hassle.

It's worth taking these factors into consideration if you're looking at using gas profile cutting. There are alternatives, but for heavy duty, indistrial applications, flame cutting is always a popular process.